US20020197941A1

US20020197941A1 - Flexible adapter for use with rotary tools

Info

Publication number: US20020197941A1
Application number: US09/886,732
Authority: US
Inventors: Antonino Bruno
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-06-20
Filing date: 2001-06-20
Publication date: 2002-12-26

Abstract

A flexible adapter for use with rotary tools typically employed in a construction environment for driving a rotary tool by a prime mover. In its most fundamental embodiment, the flexible adapter for use with rotary tools exhibits a construction having a mechanical rotary tool such as a wire brush tool or a sanding disc tool for use on a work surface. A prime mover such as an electric drill is supplied for providing rotary motion to the mechanical rotary tool. A flexible member such as a suitable length of stainless steel cable is provided for connecting the mechanical rotary tool to the prime mover for driving the mechanical rotary tool and for absorbing the torque generated by the prime mover to ensure control of and to improve the efficiency of the mechanical rotary tool.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to mechanical tool devices.

More specifically, the present invention relates to methods and apparatus for a flexible adapter for use with rotary tools that typically operate at high speed for sanding, grinding, and scraping, wherein the flexible adapter drives a rotary tool and absorbs the torque generated by a prime mover for ensuring control of and improving the efficiency of the rotary tools.

2. Background Art

The prior art is directed to methods and apparatus for operating high speed rotary tools typically used for grinding, sanding and scraping wood and metal surfaces.

High speed rotary tools are commonly used to grind, sand and scrap surfaces for the purpose of, for example, removing paint, rust or corrosion, smoothing a surface in preparation of refinishing and/or painting it, or to alter the surface shape as in making replacement or custom pieces from wood. Typically, this arrangement includes a prime mover which can be an electrically rotary device such as an electric drill. Many electrical drills for use in this manner are manufactured and commercially available in hardware stores and other retail outlets.

Typically, this type of tool arrangement comprises an electrical drill energized from a standard 120 volt, 60 Hz, single phase electrical outlet commonly found in residential households. The rotary output section of the electric drill typically includes a set of jaws which can be adjusted with a hand tool commonly referred to as a drill “chuck”. A mechanical rotary tool such as a grinding or sanding device typically includes a rigid output shaft. The rigid output shaft is usually fashioned from high strength steel and is fixedly connected to the mechanical rotary tool. The rigid output shaft is then positioned into the set of jaws of the rotary output section of the electric drill. The set of jaws are then tightened around the rigid output shaft of the mechanical rotary tool by using the drill “chuck”. Thereafter, operation of the electrical drill results in high speed rotation of the mechanical rotary tool which can then be used for grinding, sanding and scraping.

Examples of this type of prior art mechanical rotary tool will now be offered. A first example includes a sanding disk pad while a second example includes a wire brush. In the first example, the structure of the sanding disk pad includes a rigid output shaft which is fixedly mounted to a flat metal disk at a first end thereof. The flat metal disk is embedded in a hard disk which can be fashioned from a rigid synthetic material. Mounted on the front surface of the hard disk with an adhesive is a cushioning surface. Affixed to the front of the cushioning surface is a sanding medium comprised of a flat sanding paper. The flat sanding medium is removably attached to the cushioning surface by a sticky compound placed on one side of the sanding medium. The sanding medium is available in different sizes and can easily be replaced. A second end of the rigid output shaft of the sanding disk pad is positioned within and secured by the jaws of the rotary output section of the electric drill. Operation of the electric drill causes the sanding disk pad to rotate at a high speed for sanding, for example, a wood or metal surface.

In the second example, the structure of the wire brush also includes a rigid output shaft. The wire brush includes a casing having a center penetration for accommodating a first end of the rigid output shaft. The first end of the rigid output shaft passes through the center penetration of the casing. A plurality of wire brush terminal ends are held in position within the casing by a circular disk. The first end of the rigid output shaft is swaged to the circular disk which is positioned to securely hold the wire brush terminal ends in position. The wire brush terminal ends extend outward away from the rigid output shaft. A second end of the rigid output shaft is then positioned within and secured by the jaws of the rotary output section of the electric drill. Operation of the electric drill causes the wire brush to rotate at high speed so that the wire brush terminal ends can be utilized to, for example, scrap seasoned paint from a metal surface.

It is noted that both the sanding disk pad of the first example and the wire brush of the second example include a rigid output shaft. Further, the rigid output shaft of each mechanical rotary tool is positioned within the rotary output section of the electric drill in a perpendicular or orthogonal manner. A main problem associated with the mechanical rotary tools discussed herein above is the lack of control of the sanding disk pad and/or the wire brush. When the sanding disk pad or the wire brush attached to and driven by the electrical drill is applied orthogonally to a wooden or metal surface, the centrifugal force (i.e., outward force) created by the rotary torque of the electric drill prevents one from controlling the sanding disk pad or the wire brush. The sanding disk pad and/or the wire brush when applied perpendicularly to a work surface, begins to “wonder away” from the point of interest and the user loses control of the mechanical rotary tool. In addition, because of the loss of control of the mechanical rotary tool, only a portion of the surface of the sanding disk pad or the wire brush actually contacts the work surface. Consequently, the sanding, grinding or scraping of the work surface is irregular, not smooth, and unsuitable for resurfacing.

A third example of a mechanical rotary tool driven by an electric drill is an apparatus used for sanding or polishing work surfaces. In this example, the mechanical rotary tool includes a rigid output shaft or spindle typically comprised of steel. A first end of the rigid output shaft is connected to a flexible poly cover or hood formed in the shape of a dome. The center of the dome-shaped poly cover includes a rubber ball shaped structure having a penetration formed therein. The first end of the rigid output shaft is anchored within the penetration of the rubber ball shaped structure at the top of the dome-shaped poly cover. At the lower portion of the rubber ball shaped structure is a circular valley or depression formed in the dome-shaped poly cover. The bottom of the dome-shaped poly cover is connected to a back support pad which in turn is connected to a sanding or polishing medium. A second end of the rigid output shaft is inserted into and secured by the jaws of the rotary output section of the electric drill.

Operation of the electric drill results in rotation of the dome-shaped poly cover, back support pad and the sanding or polishing medium. The circular valley or depression formed at the bottom of the rubber ball structure at the top of the dome-shaped poly cover provides some flexibility in this mechanical rotary tool. Unfortunately, the material that forms the poly cover (i.e., rubber, polyethylene, polyurethane or other synthetic material) tends to wear and deteriorate from the high speed rotations of the prime mover. The electric drill applies a continuous torque on the depression formed in the poly cover. Additionally, the rubber, polyethylene or polyurethane poly cover will dry and crack due to extended exposure to the elements. Further, the stress applied to the interface between the poly cover and the first end of the rigid output shaft, plus the effects of exposure to the elements results in cracks forming within the depression formed in the poly cover. These “stress cracks” also form at the interface of the poly cover and the first end of the rigid output shaft. Eventually, the dome-shaped poly cover will fail due to these problems.

Thus, there is a need in the art for a flexible adapter for use with rotary tools that includes a flexible member that serves as a flexible interface between a high speed prime mover such as an electric drill and a mechanical rotary tool such as a wire brush assembly or a sanding disk pad. The flexible member is securely mounted to both the prime mover and the mechanical rotary tool such that the flexible member absorbs the rotary torque of the prime mover for reducing the likelihood of failure at the interface between the flexible member and the mechanical rotary tool.

DISCLOSURE OF THE INVENTION

Briefly, and in general terms, the present invention provides a new and improved flexible adapter for use with rotary tools typically employed in a construction environment for driving a rotary tool and for absorbing the torque generated by the prime mover to ensure control of and improve the efficiency of the rotary tool. The invention includes a mechanical rotary tool such a wire brush tool or a sanding disc tool for use on wood and/or metal surfaces. The mechanical rotary tool is typically driven by a high speed prime mover. In the present invention, the rotary tool remains orthogonal to the work surface while the prime mover is held at an angle. This design avoids the problem associated with loss of control of the mechanical rotary tool during operation. Generally, the prime mover is electrically powered and can be, for example, a high speed electric drill. The mechanical rotary tool is connected to the prime mover via a flexible member which can be a suitable length of high strength, stainless steel cable.

In a preferred embodiment, the mechanical rotary tool comprises a wire brush tool for use in scraping a work surface such as, for example, removing paint or rust from a metal surface. The wire brush tool can include a steel shallow casing having a first penetration formed there through. A cylindrical metal grommet is fitted through the first penetration formed in the steel shallow casing. The metal grommet includes a steel flange formed on one end thereof which is mounted against an external surface of the steel shallow casing. The entire cylindrical metal grommet is hollow including the steel flange formed on the one end. Thus, a cylindrical passageway is formed through the entire length of the metal grommet. Mounted adjacent to the steel shallow casing is a circular disc formed of steel and having a second penetration formed there through. Likewise, mounted adjacent to the circular disc is a steel disc having a third penetration formed there through.

After being passed through the first penetration in the shallow casing, the metal grommet is passed through the second penetration formed within the circular disc, and then the third penetration formed within the steel disc. Thereafter, each of the first, second and third penetrations formed within the shallow casing, circular disc, steel disc, respectively, are in alignment. A plurality of stainless steel wire brush stands are captured between the shallow casing and the circular disc.

The plurality of wire brush strands extend outward from the wire brush tool for use in, for example, scraping paint or rust from a metal surface.

The flexible member typically can include “7×7 left lay” stainless steel aircraft cable with radially open braids at one end thereof. The stainless steel cable is selected to have a suitable length and diameter. A closed end stop is attached, as by compression, at a terminal end of the flexible stainless steel cable for interfacing with the jaws of a rotary output section of the electric drill. The closed end stop also serves to prevent the braids of the stainless steel cable from unraveling or separating from one another. The stainless steel cable is then directed through the cylindrical passageway of the metal grommet. Thus, the stainless steel cable also passes through the first, second and third penetrations of the shallow casing, circular disc, and steel disc, respectively, by virtue of it passing through the metal grommet. The end of the metal grommet is then forcibly opened, i.e., turned-up, against the steel disc. The circular disc, wire brush strands and the shallow casing are then positioned between the turned-up end and the flange of the metal grommet. The braids of the stainless steel cable are then separated and spread outward and the steel disc is then swaged over the radially open braids and the turned-up end of the metal grommet. The entire wire brush tool is now securely assembled and ready to be employed, for example, in scraping paint or rust from a metal surface.

The present invention is generally directed to a flexible adapter for use with rotary tools typically utilized in a construction environment for driving the mechanical rotary tool and for absorbing the torque generated by the prime mover to ensure control of and improve the efficiency of the rotary tool. In its most fundamental embodiment, the flexible adapter for use with rotary tools exhibits a construction having a mechanical rotary tool for use on a work surface. A prime mover is supplied for providing rotary motion to the mechanical rotary tool. A flexible member is provided for connecting the mechanical rotary tool to the prime mover for driving the mechanical rotary tool and for absorbing the torque generated by the prime mover to ensure control of and to improve the efficiency of the mechanical rotary tool.

In an alternative embodiment, the mechanical rotary tool comprises a sanding disc tool for use in sanding a work surface such as, for example, a wood surface prior to applying a finishing coat of paint thereto. The sanding disc tool can include a base integrally formed with a hard disc which provides structural stability and support to the sanding disc tool. Both the base and the hard disc can be comprised of a high strength synthetic material such as polyethylene. Mounted on the forward surface of the hard disc (i.e., on the surface of the hard disc opposite to that upon which the base appears) is a soft pad and a sanding disc surface. The soft pad provides a cushioning interface that separates the sanding disc surface from the hard disc to protect the work surface being sanded. (It is noted that the sanding disc surface could alternately be a polishing surface.)

In the alternative embodiment, a flexible member is employed to connect the sanding disc tool to a prime mover such as an electric drill. The flexible member can be comprised of a (“7×7 left lay”) stainless steel aircraft cable of suitable length and diameter. At one end of the stainless steel cable, the braids are separated and embedded in the integral structure of the base and hard disc. The other end of the stainless steel cable includes a closed end stop affixed thereto, as by compression, for preventing the braids of the cable from unraveling, and for interfacing with the jaws of the rotary output section of the electric drill. The stainless steel cable serves to drive the sanding disc tool and to absorb the torque generated by the electric drill for ensuring the control of and for improving the efficiency of the sanding disc tool.

These and other objects and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate the invention, by way of example.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a flexible adapter for use with rotary tools showing a mechanical rotary tool in block form connected to a prime mover (such as a drill chuck) via a flexible cable and a closed end stop. [0023]
FIG. 2 is a perspective view of the flexible adapter for use with rotary tools of FIG. 1 showing a wire brush rotary tool attached to the flexible cable and the closed end stop for connection to the prime mover. [0024]
FIG. 3 is an end view of the wire brush rotary tool connected to the flexible adapter for use with rotary tools of FIG. 1 showing the plurality of wire brush strands and a circular disc utilized for securing the wire brush strands in position. [0025]
FIG. 4 is a cross sectional view of the flexible adapter for use with rotary tools taken along line [0026] 4-4 of FIG. 2 showing the plurality of wire brush strands secured between a shallow casing and the circular disc held together by a metal grommet including the flexible cable passing through the metal grommet.
FIG. 5 is a detail view of the metal grommet utilized with the wire brush rotary tool shown in FIG. 4 including a retaining flange on one end thereof. [0027]
FIG. 6 is a perspective view of an alternative embodiment of the flexible adapter for use with rotary tools of the present invention showing a sanding disk rotary tool attached to the flexible cable and the closed end stop. [0028]
FIG. 7 is a side elevation view of the flexible adapter for use with rotary tools of FIG. 6 showing a sanding disc mounted on a soft pad which is mounted upon the integral combination of a hard disc and a base element, the base element being attached to the flexible cable and closed end stop. [0029]
FIG. 8 is a top plan view of the flexible adapter for use with rotary tools of FIG. 7 as seen from the base element showing a plurality of seven open braids of the flexible cable mounted underneath the top surface of the base element and hard disc for securing the flexible cable thereto. [0030]
FIG. 9 is a cross-sectional view of the flexible adapter for use with rotary tools taken along line [0031] 9-9 of FIG. 6 showing the plurality of open braids of the flexible cable embedded within the base element.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a [0032] flexible adapter 100 for use with rotary tools typically employed in a construction environment for driving a rotary tool 102 and for absorbing the torque generated by a prime mover 104 to ensure control of and to improve the efficiency of the rotary tool 102.
The invention is illustrated in generalized block form in FIG. 1 and includes the [0033] mechanical rotary tool 102 which can be any suitable tool that is driven by rotary motion provided by the prime mover 104. Such mechanical tools could include, for example, a wire brush, a sanding disc or other suitable tool. The prime mover 104 can be, for example, an electric drill which is represented in FIG. 1 by a drill chuck 106. The drill chuck 106 is normally located at a forward end of the electric drill and typically includes a plurality of segments 108 which form a set of jaws 110. The segments 108 of the drill chuck 106 are repositionable by use of an adjustment key 112. The key 112 includes a bevel gear 114 at the end thereof for meshing with a corresponding bevel gear (not shown) countersunk beneath the plurality of segments 108 of the drill chuck 106. Operation of the adjustment key 112 in a clockwise or a counter clockwise direction causes the plurality of segments 108 of the set of jaws 110 to open or close.
The [0034] mechanical rotary tool 102 is connected to the drill chuck 106 of the prime mover electric drill 104 via a flexible member 116 as is shown in FIG. 1. One of the functions of the flexible member 116 is to transmit the rotary motion of the electric drill 104 to the mechanical rotary tool 102. A second function of the flexible member 116 is associated with overcoming the problem of losing control of the mechanical rotary tool 102 caused by the centrifugal force created by the rotary torque of the electric drill 104 when the rotary tool 102 is applied perpendicularly to the work surface. Thus, a second function of the flexible member 116 is to prevent the mechanical rotary tool 102 from “wondering away” from the point of interest on the work surface. This is accomplished by selecting a suitable material for the flexible member 116 which will absorb the torque generated by the electric drill 104. This design will then ensure the control of and improve the efficiency of the mechanical rotary tool 102.
An example of a suitable material for comprising the [0035] flexible member 116 is a high strength flexible, stainless steel cable as shown in FIG. 1. The flexible stainless steel cable 116 can, for example, be a (7×7 “left lay”) stainless steel aircraft cable having approximately a 1″ length and a {fraction (3/16)}″ diameter, and a plurality of radially open braids at a first terminal end 118 (as will be discussed in more detail with regard to FIGS. 4 and 8 herein below). Aircraft cable is suitable for use as the flexible member 116 since it is very strong and flexible. The descriptive feature (7×7, “left lay”) indicates that the cable 116 includes seven strands per braid and seven braids per cable. Further, the cable construction must be of the “left lay” design in order to avoid unraveling of the flexible stainless steel cable 116 when the electrical drill 104 rotates at rated speed in the clockwise direction. The flexible stainless steel aircraft cable 116 suitable for use in the present invention is available from the cable manufacturer Loos & Company, Wire Rope Division, having offices located at One Cable Road, Pomfret, Conn. 06258 U.S.A.
The first [0036] terminal end 118 of the flexible stainless steel cable 116 is anchored to the mechanical rotary tool 102 as is symbolically shown in FIG. 1 but shown more clearly in FIGS. 4 and 8. Likewise, a second terminal end 120 of the flexible stainless steel cable 116 is capped with a closed end stop 122 also shown in FIG. 1. The closed end stop 122 typically will be comprised of stainless steel and have a ⅜″ diameter and a ½″ length. The stainless steel closed end stop 122 is swaged to the second terminal end 120 of the flexible stainless steel cable 116 with a fifty ton punch press. The closed end stop 122 serves to (a) provide a convenient interface between the stainless steel cable 116 and the plurality of segments 108 that form the set of jaws 110 of the drill chuck 106 for connecting the mechanical rotary tool 102 to the electric drill 104, and (b) to prevent the second terminal end 120 of the flexible stainless steel cable 116 from unraveling.
It is emphasized that the flexible [0037] stainless steel cable 116 not only drives the mechanical rotary tool 102 from the electric drill 104, but in addition the flexibility of the cable 116 also enables it to absorb the torque generated by the electric drill 104. Consequently, the mechanical rotary tool 102 will remain flat on the work surface while the electric drill 104 is held at an angle while in operation. Further, the rotary tool 102 will remain flat on the work surface even if the work surface is vertical, horizontal, or positioned at an angle. Under these conditions, the problem of the mechanical rotary tool 102 “wondering away” from the point of interest which previously resulted in the loss of control of the rotary tool 102 is eliminated. Since the mechanical rotary tool 102 will remain orthogonal (i.e., perpendicular) to the work surface during operation of the electric drill 104 while the flexible stainless steel cable 116 is at an angle, then the rotary tool 102 can be employed for hard-to-reach areas.
We will now turn our attention to a preferred embodiment of the [0038] flexible adapter 100 for use with rotary tools as shown in FIGS. 2-5. The prime mover 104 in the preferred embodiment is the electric drill as described in FIG. 1 and thus will not be further described here. Likewise, the flexible member 116 and the closed end stop 122 are identical in construction to that described in FIG. 1 but with further description as to the attachment of the first terminal end 118 of the flexible member 116 to the mechanical rotary tool 102. As in the description of FIG. 1, the flexible member 116 can be a high strength flexible, stainless steel aircraft cable which serves to (a) transmit the rotary motion of the electric drill 104 to the mechanical rotary tool 102, and (b) prevent the mechanical rotary tool 102 from “wondering away” from the point of interest on the work surface by absorbing the torque generated by the electric drill 104 for ensuring the control of and improving the efficiency of the mechanical rotary tool 102. Thus, the rotary torque of the electric drill 104 is absorbed by the flexible stainless steel aircraft cable 116 and not the mechanical rotary tool 102.
The [0039] mechanical rotary tool 102 illustrated in the preferred embodiment of the flexible adapter 100 for use with rotary tools is directed to a wire brush tool best shown in FIGS. 2-4. The wire brush tool 102 is referred to as a heavy duty tool or a hard tool because it is typically used to scrap paint or rust from metal work surfaces. Consequently, the electric drill 104 used to provide rotary motion to the wire brush tool 102 may be of the high speed variety. The wire brush tool 102 includes a shallow casing 126 having a first penetration 128 formed there through. The first penetration 128 is located approximately at the center of the shallow casing 126 shown in FIG. 4. The shallow casing 126 is generally cup-shaped as shown in FIG. 2, comprised of steel, and serves as a partial outer housing. The steel, cup-shaped shallow casing 126 includes an external surface 130 and an internal surface 132 as shown in FIG. 4.
Mounted within the [0040] first penetration 128 at approximately the center of the steel, cup-shaped shallow casing 126 is a metal grommet 134. The metal grommet 134 is cylindrical in shape, typically fashioned from steel, and includes a steel flange 136 formed on a first end 138 thereof (see FIG. 5). The metal grommet 134 is hollow throughout its entire length including the flange 136. Thus, a cylindrical passageway 140 shown best in FIG. 5 is formed throughout the entire length of the metal grommet 134. Once the metal grommet 134 is positioned within the first penetration 128, the flange 136 is mounted against the external surface 130 of the steel, shallow casing 126. Mounted adjacent to the internal surface 132 of the steel, shallow casing 126 is a circular disc 142 as shown in FIG. 4. The circular disc 142 is comprised of steel and includes a second penetration 144 essentially aligned with the first penetration 128 of the shallow casing 126. A plurality of wire brush strands 146 is captured between the internal surface 132 of the shallow casing 126 and the circular disc 142 as is shown in FIG. 4. The plurality of wire brush strands 146 are comprised of steel and extend outward from the wire brush tool 102, i.e., away from the internal surface 132 of the steel shallow casing 126 and away from the steel circular disc 142, for use in scraping a metal work surface.
After passing through the [0041] first penetration 128 in the steel shallow casing 126, the metal grommet 134 is then passed through the second penetration 144 formed through the steel circular disc 142. Mounted adjacent to the steel circular disc 142 (furthest from the plurality of wire brush strands 146 and the internal surface 132 of the steel shallow casing 126) is a steel disc 148 as is clearly shown in FIG. 4. A third penetration 150 is formed in the steel disc 148 which is aligned with the second penetration 144 formed in the circular disc 142. The metal grommet 134 is then passed through the third penetration 150 formed through the steel disc 148. A second end 152 of the metal grommet 134 (shown best in FIG. 5) is then forcibly opened, i.e, turned upwards, against the steel disc 148. Thereafter, the circular disc 142, the plurality of wire brush strands 146, and the shallow casing 126 are captured between the second end 152 and the flange 136 of the metal grommet 134.
At this point, the first [0042] terminal end 118 of the flexible stainless steel cable 116 is passed through the cylindrical passageway 140 formed through the entire length of the metal grommet 134. In effect, the flexible stainless steel cable 116 is being passed through the first penetration 128 of the shallowing casing 126, the second penetration 144 through the circular disc 142, and the third penetration 150 through the steel disc 148. A plurality of stainless steel braids 154 at the first terminal end 118 of the stainless steel cable 116 is then separated and radially spread outward as is shown in FIG. 4. The number of stainless steel braids 154 is typically seven as shown in FIGS. 2 and 3. Thereafter, the steel disc 148 is swaged over the radially open braids 154 and the second end 152 of the metal grommet 134. The entire wire brush tool 102 (including the shallow casing 126, plurality of wire brush strands 146, circular disc 142, metal grommet 134, flexible stainless steel cable 116, and steel disc 148) is now assembled and secured as best shown in FIGS. 2 and 4. The closed end stop 122 compressed onto the flexible stainless steel cable 116 is then inserted into the jaws 110 of the drill chuck 106 of the electric drill 104 as illustrated in FIG. 1. The plurality of segments 108 of the drill chuck 106 are then tightened down onto the closed end stop 122 with the adjustment key 112. The wire brush tool 102 can now be operated by the electric drill 104 and be employed to, for example, scrap paint from a metal work surface.
An alternative embodiment of the flexible adapter for use with rotary tools of the present invention is shown in FIGS. [0043] 6-9 and is referred to by the identification number 200. Each of the components appearing in the alternative embodiment 200 that correspond in structure and function to those components appearing in the preferred embodiment 100 is identified by the corresponding number of the 200 series.
The components appearing in the alternative embodiment of the [0044] flexible adapter 200 for use with rotary tools that correspond in structure and function to those components appearing in the preferred embodiment are set forth at this time. Those components include a mechanical rotary tool 202 for use on a work surface. In the flexible adapter 200 of the alternative embodiment of the present invention, the mechanical rotary tool 202 is directed to a sanding disc tool which will be discussed in detail herein below. A prime mover 204 in the alternative embodiment is the electric drill as described in FIG. 1. The electric drill 204 includes a drill chuck 206, a plurality of segments 208, a set of jaws 210, an adjustment key 212, and a bevel gear 214. Each of these components are identical to and perform the same function as their corresponding components as described with reference to FIG. 1. The sanding disc tool 202 is used for sanding a work surface. The electric drill 204 serves to provide rotary motion to the sanding disc tool 202. The drill chuck 206 including the plurality of segments 208 that form the set of jaws 210 are used to grasp a flexible member 216 that is connected to and employed to drive the rotary tool 202. The adjustment key 212 and the bevel gear 214 are employed to adjust, i.e., to either open or close, the plurality of segments 208 of the set of jaws 210 for grasping and releasing the flexible member 216.
Likewise, the [0045] flexible member 216 and a closed end stop 222 employed in the alternative embodiment of the flexible adapter 200 are identical in construction to that described in the preferred embodiment 100. The flexible member 216 is a high strength flexible, stainless steel cable as shown in FIGS. 6, 7 and 9. The flexible stainless steel cable 216 can be, for example, a (7×7 “left lay”) stainless steel aircraft cable having approximately a 1″ length and a {fraction (3/16)}″ diameter, and a plurality of radially open braids at a first terminal end 218 (as will be discussed in more detail with regard to FIG. 8 herein below as it relates to connecting to the sanding disc tool 202). The descriptive feature (7×7, “left lay”) indicates that the cable 216 includes seven strands per braid and seven braids per cable. The cable construction must be of the “left lay” design to prevent unraveling of the flexible stainless steel cable 216 during the rotation of the electrical drill 204 at rated speed in the clockwise direction. The flexible stainless steel aircraft cable 216 suitable for use in the present invention is available from the cable manufacturer Loos & Company, Wire Rope Division, having offices located at One Cable Road, Pomfret, Conn. 06258 U.S.A. The flexible, stainless steel cable 216 serves to (a) transmit the rotary motion of the electric drill 204 to the sanding disc tool 202, and (b) prevent the sanding disc tool 202 from “wondering away” from the point of interest on the work surface by absorbing the torque generated by the electric drill 204 for ensuring the control of and improving the efficiency of the sanding disc tool 202. Thus, the rotary torque of the electric drill 204 is absorbed by the flexible stainless steel aircraft cable 216 and not the sanding disc tool 202.
The first [0046] terminal end 218 of the flexible stainless steel cable 216 is anchored to the sanding disc tool 202 and will be further discussed in relation to FIGS. 8 and 9. Likewise, a second terminal end 220 of the flexible, stainless steel cable 216 is capped with the closed end stop 222 also shown in FIGS. 6, 7 and 9. The closed end stop 222 typically will be comprised of stainless steel and have a ⅜″ diameter and a ½″ length. The stainless steel closed end stop 222 is swaged to the second terminal end 220 of the flexible, stainless steel cable 216 with a fifty ton punch press. The closed end stop 222 serves to (a) provide a convenient interface between the stainless steel cable 216 and the plurality of segments 208 that form the set of jaws 210 of the drill chuck 206 for connecting the sanding disc tool 202 to the electric drill 204, and (b) to prevent the second terminal end 220 of the flexible stainless steel cable 216 from unraveling.
The [0047] sanding disc tool 202 of the flexible adapter 200 will now be described in detail. The sanding disc tool 202 includes a base 260 as shown in FIGS. 7, 8 and 9. The base 260 is a raised circular portion which is mounted upon and integrally formed with a hard disc 262 as is clearly shown in FIGS. 7 and 9. The interface between the base 260 and the hard disc 262 is defined by a curved surface 264 as is shown in FIGS. 7 and 9.
The integral combination of the [0048] base 260 and the hard disc 262 is comprised of a very hard synthetic (plastic) material such as, for example, polyethylene or other equally suitable material. A function of the base 260 and hard disc 262 of the 203 sanding disc tool 202 is to interconnect with the flexible, stainless steel cable 216. This is accomplished in the following way. The first terminal end 218 of the flexible stainless steel cable 216 includes a plurality of stainless steel braids 254 as is clearly shown in FIG. 8 and also in FIG. 9. In the alternative embodiment of the flexible adapter 200, seven stainless steel braids 254 extending from the first terminal end 218 are separated, embedded and anchored in the integral structure of the base 260 and the hard disc 262. However, fewer than seven of the stainless steel braids 254 can be separated, embedded and anchored in the base 260 and hard disc 262 and the flexible stainless steel cable 216 will be adequately interconnected to the sanding disc tool 202.
The [0049] flexible adapter 200 for use with the sanding disc tool 202 exhibits the hard, rigid plastic base 260 integrally fused with the rigid plastic hard disc 262 in which the braids 254 of the stainless steel cable 216 are buried in a 360° pattern within the hard plastic base 260 (see FIG. 8). An additional function of the hard disc 262 is to provide stability to the entire sanding disc tool 202. This combination creates a construction that securely interconnects the flexible, stainless steel cable 216 to the sanding disc tool 202 as is best shown in FIG. 9. As a result, the sanding disc tool 202 is driven, via the stainless steel cable 216, by the rotary motion developed by the electric drill 204 (as is illustrated in FIG. 1).
It is important to note that the rotary torque developed by the electric drill [0050] 204 is absorbed by the flexible, stainless steel cable 216 and not the rigid base 260. The rigid interconnection between the flexible, stainless steel cable 216 and the rigid base 260 described above prevents the rotary torque developed by the electric drill 204 from being absorbed by the base 260. Consequently, the integral combination of the base 260 and the hard disc 262 is less likely to fail during operation. Further, the sanding disc tool 202 will remain flat on the work surface while the electric drill 204 is held at an angle during operation even if the work surface is vertical, horizontal, or positioned at an angle. Under these conditions, the problem of losing control of the sanding disc tool 202 (i.e., “wondering away”) is eliminated. Additionally, a longer flexible, stainless steel cable 216 can be employed for accessing hard-to-reach areas.
Mounted to the hard disc [0051] 262 (on a side of the hard disc 262 opposite to the base 260) is a soft pad 266 as shown clearly in FIGS. 6 and 9. The function of the soft pad 266 is to provide a cushioning interface between the hard disc 262 and a sanding disc surface 268 as shown in FIGS. 6, 7 and 9. Under these conditions, the work surface is protected from the hard disc 262. The soft pad 266 can be affixed to the hard disc 262 by any convenient method such as, for example, the use of a first adhesive 270 which fuses the soft pad 266 to the hard disc 262. The soft pad 266 can be comprised of any of a plurality of spongy or fibrous type materials available in the marketplace that will adhere to the hard disc 262 with the assistance of the first adhesive 270. The sanding disc surface 268 is employed to sand or smooth a work surface (i.e., typically wood). The sanding disc surface 268 is replaceable and typically will be comprised of a paper disc having a sanding surface 272 on a first side and a sticky adhesive surface 274 on a second side. The sticky adhesive surface 274 of the sanding disc surface 268 is utilized to hold the sanding disc surface 268 to the soft pad 266. Once the sanding disc surface 268 has been worn down, it can be conveniently removed by peeling the sticky adhesive surface 274 from the soft pad 266 and then replaced with a duplicate sanding disc surface 268.
At this point, the [0052] closed end stop 222 compressed onto the flexible stainless steel cable 216 is inserted into the jaws 210 of the drill chuck 206 of the electric drill 204 as previously described. The plurality of segments 208 of the drill chuck 206 are then tightened down onto the closed end stop 222 with the adjustment key 212. The sanding disc tool 202 can now be operated by the electric drill 204 and be employed to, for example, sand a wood work surface. It should be noted that the alternative embodiment of the flexible adapter 200 has been described as having a sanding disc tool 202. It is within the scope of the present invention to employ a polishing disc tool as the mechanical rotary tool 202 in lieu of the sanding disc tool. Under these conditions, a polishing disc surface would replace the sanding disc surface 268 described herein above.
The present invention provides novel advantages over other conventional systems for driving rotary tools known in the prior art. A main advantage of the [0053] flexible adapter 100 for use with rotary tools of the present invention is that a mechanical rotary tool 102 such as a wire brush tool or a sanding disc tool can (a) be driven by a prime mover 104 such as an electrical drill via a flexible member 116 such as a flexible stainless steel cable, where (b) the mechanical rotary tool 102 remains orthogonal (i.e., flat or perpendicular) to the work surface while the prime mover 104 is simultaneously at an angle to the work surface, where (c) the flexible member 116 absorbs the torque generated by the prime mover to ensure control of and to improve the efficiency of the mechanical rotary tool 102, by (d) eliminating the “wondering away” of the mechanical rotary tool 102 caused by the centrifugal force generated by the prime mover 104. The ability to retain the mechanical rotary tool 102 orthogonal to the work surface increases the surface area of the rotary tool 102 that contacts the work surface thus improving the overall efficiency. Further, when the torque generated by the prime mover 104 is absorbed by the flexible member 116 instead of the rotary tool 102, control is improved and failure of the rotary tool 102 is minimized. Additionally, the flexible member 116 can be lengthened which enables the rotary tool 102 to be utilized for hard-to-reach areas on the work surface.
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility. [0054]
It is therefore intended by the appended claims to cover any and all such modifications, applications and embodiments within the scope of the present invention. Accordingly,[0055]

Claims

What is claimed is:

1. A flexible adapter for use with rotary tools comprising:

a mechanical rotary tool for use on a work surface;

a prime mover for providing rotary motion to said mechanical rotary tool; and

a flexible member for connecting said mechanical rotary tool to said prime mover for driving said rotary tool and for absorbing the torque generated by said prime mover to ensure control of and to improve the efficiency of said mechanical rotary tool.

2. The flexible adapter of claim 1 wherein said prime mover comprises an electric drill.

3. The flexible adapter of claim 1 wherein said flexible member is comprised of high strength stainless steel cable.

4. The flexible adapter of claim 1 further including a closed end stop affixed to a terminal end of said flexible member for interfacing with said prime mover.

5. A flexible adapter for use with rotary tools comprising:

a wire brush tool for use in scraping a work surface;

a prime mover for providing rotary motion to said wire brush tool; and

a flexible member for connecting said wire brush tool to said prime mover for driving said wire brush tool and for absorbing the torque generated by said prime mover to ensure control of and to improve the efficiency of said wire brush tool.

6. The flexible adapter of claim 5 wherein said wire brush tool further includes a shallow casing having a penetration formed there through.

7. The flexible adapter of claim 6 further including a metal grommet positioned through said penetration formed in said shallow casing, said metal grommet being hollow and including a flange mounted against an external surface of said shallow casing.

8. The flexible adapter of claim 7 wherein said flexible member passes through said hollow metal grommet.

9. The flexible adapter of claim 5 wherein said wire brush tool further includes a plurality of wire brush strands extending therefrom for scraping said work surface.

10. The flexible adapter of claim 9 wherein said plurality of wire brush strands are captured between a shallow casing and a circular disc by a metal grommet.

11. The flexible adapter of claim 5 wherein said flexible member is comprised of high strength stainless steel cable.

12. The flexible adapter of claim 11 further including a closed end stop affixed to a terminal end of said stainless steel cable for interfacing with said prime mover.

13. The flexible adapter of claim 5 wherein said prime mover comprises an electric drill.

14. A flexible adapter for use with rotary tools comprising:

a sanding disc tool for use in sanding a work surface;

a prime mover for providing rotary motion to said sanding disc tool; and

a flexible member for connecting said sanding disc tool to said prime mover for driving said sanding disc tool and for absorbing the torque generated by said prime mover to ensure control of and to improve the efficiency of said sanding disc tool.

15. The flexible adapter of claim 14 wherein said sanding disc tool further includes a base integrated with a hard disc for providing structural support to said sanding disc tool.

16. The flexible adapter of claim 15 wherein said sanding disc tool further includes a soft pad and a sanding disc surface affixed to said hard disc for sanding said work surface.

17. The flexible adapter of claim 14 wherein said flexible member is comprised of high strength stainless steel cable.

18. The flexible adapter of claim 17 wherein said stainless steel cable includes a plurality of open braids embedded within a base integrated with a hard disc of said sanding disc tool.

19. The flexible adapter of claim 17 further including a closed end stop affixed to a terminal end of said stainless steel cable for interfacing with said prime mover.

20. The flexible adapter of claim 14 wherein said prime mover comprises an electric drill.